Compliant pin power inductor with battery interface

ABSTRACT

A power inductor for an electric power steering system includes a base structure. The power inductor also includes a power coil secured to the base structure. The power inductor further includes a connector terminal extending from the base structure for connection to a circuit board. The power inductor yet includes a power terminal for connection to a power source, the power terminal and the power coil being integrated into a single assembly.

CROSS-REFERENCE TO RELATED APPLICATION

This patent application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 63/001,786, filed Mar. 30, 2020, the entire disclosure of which is incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The present disclosure relates to vehicle steering power pack assemblies and, more specifically, to power connectors for such assemblies.

BACKGROUND

A vehicle often includes an electric power steering (EPS) system to aid an operator of the vehicle in steering the vehicle. The EPS system uses sensors to detect a position and torque of a steering column and supply a signal to an electric motor to cause the electric motor to supply additional torque to assist the operator in steering the vehicle. The additional torque supplied to assist the operator in steering the vehicle can vary based on vehicle characteristics, driving conditions, road conditions, and the like.

The EPS system can utilize a controller to receive signals from sensors, analyze the signals, and control the electric motor. The controller board is connected to a motor housing via a tray, which may be referred to herein as a connector plate. Together, these components maybe referred to as a power pack assembly that provides electrical power for one or more functions associated with the steering system. Power pack assemblies often include a circuit card or printed circuit board (PCB) with electrical connectors in electrical communication therewith.

Modem automobile architecture requires certain components, particularly electrical components to include multi-piece construction. When a component includes multi-piece construction, interconnection between the pieces can be expensive and subject to the afore-described stresses. The above-referenced circuit card/board located in a column motor power pack requires a multi-piece construction power connector. Current power inductors do not allow for a one-piece vehicle battery interface that is integrated into a coil.

SUMMARY OF THE DISCLOSURE

According to one aspect of the disclosure, a power inductor for an electric power steering system includes a base structure. The power inductor also includes a power coil secured to the base structure. The power inductor further includes a connector terminal extending from the base structure for connection to a circuit board. The power inductor yet includes a power terminal for connection to a power source, the power terminal and the power coil being integrated into a single assembly.

According to another aspect of the disclosure, a power pack assembly includes a housing extending axially about a longitudinal axis. The power pack assembly also includes a circuit board having a board main portion, a first board extended segment and a second board extended segment, the board main portion covered by the housing, the first board extended segment extending radially away from the longitudinal axis and out of the housing and uncovered by the housing, the second board extended segment extending radially away from the longitudinal axis and out of the housing and uncovered by the housing. The power pack assembly further includes at least one logic connector disposed on the first board extended segment of the circuit board. The power pack assembly yet further includes a second board extended segment extending radially away from the longitudinal axis and out of the housing and uncovered by the housing, the second board extended segment. The power pack assembly also includes a power inductor. The power inductor includes a base structure. The power inductor also includes at least one power coil wrapped around the base structure. The power further includes a connector pin terminal extending from the base structure for connection to the circuit board.

According to yet another aspect of this disclosure, electric power steering (EPS) system includes an EPS housing. The EPS system also includes a power pack assembly. The power pack assembly includes a housing having a main body extending axially from a plurality of flange portions to an end surface about a longitudinal axis, the housing operatively coupled to the EPS housing with at least one mechanical fastener extending through at least one of the flange portions. The power pack assembly also includes a circuit board having a board main portion, a first board extended segment and a second board extended segment, the board main portion covered by the housing, the first board extended segment extending radially away from the longitudinal axis and out of the housing and uncovered by the housing, and the second board extended segment extending radially away from the longitudinal axis and out of the housing and uncovered by the housing. The power pack assembly further includes at least one logic connector disposed on the first board extended segment of the circuit board. The power pack assembly yet further includes a power inductor disposed on the second board extended segment of the circuit board. The power inductor includes a base structure. The power inductor also includes a power coil secured to the base structure. The power inductor further includes a connector terminal extending from the base structure for connection to a circuit board. The power inductor yet further includes a power terminal for connection to a power source, the power terminal and the power coil being integrated into a single assembly.

These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter that is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 schematically illustrates an electric power steering (EPS) system for a vehicle;

FIG. 2 is a bottom perspective view of a power pack assembly;

FIG. 3 is a top perspective view of the power pack assembly;

FIG. 4 is an end view of a power pack assembly;

FIG. 5 is a cross-sectional view of the power pack assembly;

FIG. 6 is a partially disassembled view of the power pack assembly;

FIG. 7 is another partially disassembled view of the power pack assembly;

FIG. 8 is another partially disassembled view of the power pack assembly;

FIG. 9 is a first perspective view of a power inductor of the power pack assembly;

FIG. 10 is a second perspective view of the power inductor;

FIG. 11 is a perspective view of the power inductor prior to installation with a circuit card;

FIG. 12 is a perspective view of the power inductor after installation with the circuit card; and

FIG. 13 is a perspective view of a shroud for the power inductor.

DETAILED DESCRIPTION

Referring to the Figures, without limiting same, embodiments of the disclosure are described herein. In particular, a manual power pack assembly for an electric power steering (EPS) system are disclosed herein. Although illustrated and described in connection with a column EPS system, it is to be appreciated that other types of EPS systems (e.g., rack) may benefit from the embodiments disclosed herein. Furthermore, the illustrated steering system has a mechanical connection from the steering input device to the steering gear, but it is to be appreciated that steer-by-wire systems may also benefit from the disclosed embodiments. Therefore, the illustrated embodiment is not limiting of the particular application that the manual power pack assembly may be utilized with.

FIG. 1 is an exemplary embodiment of an electric power steering system (EPS) 40 suitable for implementation of the disclosed embodiments. The steering mechanism 36 is a rack-and-pinion type system and includes a toothed rack (not shown) within housing 50 and a pinion gear (also not shown) located under gear housing 52. As the operator input, hereinafter denoted as a steering wheel 26 (e.g. a hand wheel or the like) is turned, the upper steering shaft 29 turns and the lower steering shaft 51, connected to the upper steering shaft 29 through universal joint 34, turns the pinion gear. Rotation of the pinion gear moves the rack, which moves tie rods 38 (only one shown), in turn moving the steering knuckles 39 (only one shown), which turn steerable wheel(s) 44 (only one shown).

Electric power steering assist is provided through the control apparatus generally designated by reference numeral 24 and includes the controller 16 and an electric machine 19, which could be a permanent magnet synchronous motor, a permanent magnet direct current motor, a switched reluctance motor, or any other type of motor, are is hereinafter denoted as motor 19. The controller 16 is powered by the vehicle power supply 10 through line 12. The controller 16 receives information from sensors relating to various operating conditions and/or inputs of the EPS system 40, examples of which are illustrated and described below.

As the steering wheel 26 is turned, a torque sensor 28 senses the torque applied to the steering wheel 26 by the vehicle operator. The torque sensor 28 may include a torsion bar (not shown) and a variable resistive-type sensor (also not shown), which outputs a variable torque signal 18 to the controller 16 in relation to the amount of twist on the torsion bar. Although this is one type of torque sensor, any other suitable torque-sensing device used with known signal processing techniques will suffice. In response to the various inputs, the controller sends a command 22 to the electric motor 19, which supplies torque assist to the steering system through worm 47 and worm gear 48, providing torque assist to the vehicle steering. A feedback signal 21 is returned to the controller 16 from the electric motor 19.

It should be noted that although the disclosed embodiments are described by way of reference to motor control for electric steering applications, it will be appreciated that such references are illustrative only and the disclosed embodiments may be applied to any motor control application employing an electric motor, e.g., steering, valve control, and the like. Moreover, the references and descriptions herein may apply to many forms of parameter sensors, including, but not limited to torque, position, speed and the like. It should also be noted that reference herein to electric machines including, but not limited to, motors, hereafter, for brevity and simplicity, reference will be made to motors only without limitation.

In the control system 24 as depicted, the controller 16 utilizes the torque, position, and speed, and the like, to compute a command(s) to deliver the required output power. Controller 16 is disposed in communication with the various systems and sensors of the motor control system. Controller 16 receives signals from each of the system sensors, quantifies the received information, and provides an output command signal(s) in response thereto, in this instance, for example, to the motor 19. Controller 16 is configured to develop the necessary voltage(s) out of inverter (not shown), which may optionally be incorporated with controller 16 and will be referred to herein as controller 16, such that, when applied to the motor 19, the desired torque or position is generated. Because these voltages are related to the position and speed of the motor 19 and the desired torque, the position and/or speed of the rotor and the torque applied by an operator are determined. A position encoder is connected to the steering shaft 51 to detect the angular position. The encoder may sense the rotary position based on optical detection, magnetic field variations, or other methodologies. Typical position sensors include potentiometers, resolvers, synchros, encoders, and the like, as well as combinations comprising at least one of the forgoing. The position encoder outputs a position signal 20 indicating the angular position of the steering shaft 51 and thereby that of the motor 19.

As shown in FIGS. 2-8, a power pack assembly is shown and generally referenced with numeral 60. As described above, the power pack assembly 60 is an assembly that provides power to one or more systems of a vehicle steering system. Although illustrated and described largely as being used to power the EPS system 40, it is to be appreciated that the power pack assembly 60 may be used to power other electric systems.

The power pack assembly includes a housing 62 that mounts to a heat sink tray 64 to enclose a portion of a controller circuit card 68 and motor shaft 70 that drives the EPS system 40. The controller circuit card 68 has a main portion 72 (FIGS. 5 and 6) that is covered by the housing 62. As shown, the housing 62 has a body portion 74, an end surface 76, and a plurality of flange portions 78 located on an opposite end of the body portion 74 relative to the end surface 76. The body portion 74 comprises at least one substantially cylindrical portion, but may include one or more steps, as shown in the illustrated embodiment.

The flange portions 78 each include one or more apertures to receive mechanical fasteners for coupling the housing 62 to the heat sink tray 64 and/or to receive position locating pins or the like. The perimeter of the body portion 74 and the flange portions 78 cover the main portion 72 of the controller circuit card 68 when the housing 62 is coupled to the heat sink tray 64. However, the heat sink tray 64 and the controller circuit card 68 each include substantially corresponding segments that extend radially outwardly to positions outside of the housing 62. In other words, the heat sink tray 64 includes one or more tray extended segments 80 and the controller circuit card 68 includes one or more card extended segments 82 that each extend sufficiently to not be covered by the housing 62. These extended segments 80, 82 (FIG. 5) are therefore external to the housing 62.

The extended segments 80, 82 provide additional connection points that may be oriented based on the specifications of the overall system. Therefore, the overall power pack assembly 60 is adjustable to accommodate various orientations that would be beneficial to the system. This is in contrast to power pack assemblies that cover all of the connection points within the housing. In the illustrated embodiments, first connection points are generally referenced with numeral 90 and partially covered with a first connector shroud 92. The first connection points 90 are logic connectors that form a logic header. A second connection point 94 is a power source connection and is partially covered with a second connector shroud 96. The second connection point 94 is a power connector that is a power header and may also be referred to herein as a power inductor.

Referring now to FIGS. 9-12, the power inductor is illustrated in greater detail and is generally referenced with numeral 94, as discussed above. The power inductor 94 includes a base structure 100. A power coil 102 is secured to the base structure 100. In the illustrated embodiment, the power coil 102 is wrapped around a portion of the base structure 100 and is mechanically attached to at least one pin connector terminal 104. For example, as shown in the illustrated embodiment, four connector terminals 104 may be provided, but it is to be understood that any number of terminals are contemplated for alternative systems.

The connector terminals 104 are compliant. The pins of each connector terminal 104 are designed to carry the high current seen in electronic power steering applications with only press force to the circuit board 68 to create an electrical connection through the power coil(s) 102.

The power inductor 94 also includes at least one power terminal 108 that is used for vehicle battery power. In the illustrated embodiment, two power terminals are provided, but as with the connector terminals 104, different numbers of power terminals may be used, as one skilled in the art can readily appreciate.

FIG. 13 illustrates the second connector shroud 96 in more detail. The second connector shroud 96 covers the power inductor 94.

The integration of the power connector terminal with the power coil allows for a much smaller component to fit on the circuit card. The power coil compliant pin interface to the circuit card assembly and integration of the battery power terminals into the assembly creates an overall packaging size footprint savings.

While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description. 

Having thus described the invention, it is claimed:
 1. A power inductor for an electric power steering system comprising: a base structure; a power coil secured to the base structure; a connector terminal extending from the base structure for connection to a circuit board; and a power terminal for connection to a power source, the power terminal and the power coil being integrated into a single assembly.
 2. The power inductor of claim 1, wherein the power source is a vehicle battery.
 3. The power inductor of claim 1, wherein the connector terminal is one of four connector terminals.
 4. The power inductor of claim 1, wherein the power terminal is one of two power terminals.
 5. The power inductor of claim 1, wherein the power coil(s) are mechanically connected to the connector terminal and the power terminal.
 6. The power inductor of claim 1, wherein the connector is a solderless press fit terminal that interfaces to the circuit board.
 7. A power pack assembly comprising: a housing extending axially about a longitudinal axis; a circuit board having a board main portion, a first board extended segment and a second board extended segment, the board main portion covered by the housing, the first board extended segment extending radially away from the longitudinal axis and out of the housing and uncovered by the housing, the second board extended segment extending radially away from the longitudinal axis and out of the housing and uncovered by the housing; at least one logic connector disposed on the first board extended segment of the circuit board; a second board extended segment extending radially away from the longitudinal axis and out of the housing and uncovered by the housing, the second board extended segment; and a power inductor comprising: a base structure; at least one power coil wrapped around the base structure; a connector pin terminal extending from the base structure for connection to the circuit board.
 8. The power inductor of claim 7, wherein the power inductor further comprises a power terminal for connection to a power source, the power terminal and the power coil being integrated into a single assembly.
 9. The power inductor of claim 8, wherein the power source is a vehicle battery.
 10. The power inductor of claim 7, wherein the connector terminal is one of four connector terminals.
 11. The power inductor of claim 8, wherein the power terminal is one of two power terminals.
 12. The power inductor of claim 8, wherein the power coil(s) are mechanically connected to the connector terminal and the power terminal.
 13. The power inductor of claim 7, wherein the connector is a solderless press fit terminal that interfaces to the circuit board.
 14. The power pack assembly of claim 7, wherein the housing has a cylindrical body.
 15. An electric power steering (EPS) system comprising: an EPS housing; and a power pack assembly comprising: a housing having a main body extending axially from a plurality of flange portions to an end surface about a longitudinal axis, the housing operatively coupled to the EPS housing with at least one mechanical fastener extending through at least one of the flange portions; a circuit board having a board main portion, a first board extended segment and a second board extended segment, the board main portion covered by the housing, the first board extended segment extending radially away from the longitudinal axis and out of the housing and uncovered by the housing, and the second board extended segment extending radially away from the longitudinal axis and out of the housing and uncovered by the housing; at least one logic connector disposed on the first board extended segment of the circuit board; and a power inductor disposed on the second board extended segment of the circuit board, the power inductor comprising: a base structure; a power coil secured to the base structure; a connector terminal extending from the base structure for connection to a circuit board; and a power terminal for connection to a power source, the power terminal and the power coil being integrated into a single assembly.
 16. The EPS system of claim 15, wherein the power coil(s) are mechanically connected to the connector terminal and the power terminal.
 17. The EPS system of claim 15, wherein the connector is a solderless press fit terminal that interfaces to the circuit board. 